Extrusion process, apparatus and product

ABSTRACT

A process for the manufacture of cooked cereals or dry pet food by preparing a mixture of water and a dry premix mainly comprising cereal flour or semolina, and pressing the mixture, with the aid of a gear pump, firstly through a heat exchanger wherein it is cooked and then through an extrusion die to form an extruded product. Also, an apparatus for carrying out the process and a product obtainable by the process.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of International applicationPCT/EP01/14734 filed Dec. 11, 2001, the content of which is expresslyincorporated herein by reference thereto.

BACKGROUND ART

The present invention relates to an extrusion process for themanufacture of cooked cereals or dry pet food, an apparatus for carryingout the process and a product obtainable by the process.

U.S. Pat. No. 5,997,934 (Geromini et al.) discloses a process for themanufacture of cooked cereals or dry pet food which comprises preparinga mixture of water and a dry premix mainly comprising cereal flour orsemolina, cooking the mixture and extruding it by pressing it through anextrusion die with the aid of a gear pump.

U.S. Pat. No. 5,667,833 (Juengling et al.) discloses a process and anequipment for manufacturing pasta which comprises preparing a mixture ofcereal flour and water having a water content of 25-40%, kneading themixture and extruding it by pressing it through an extrusion die withthe aid of a gear pump.

It would be desirable to provide an extrusion process and apparatuswhich maintains the molecular structure of the starch in order tomanufacture a product with properties that are close to those of atraditional roller-dried product but superior to those of a traditionalcooked-extruded product.

As a matter of fact a traditional roller-dried product was not subjectedto any mechanical stress during its entire manufacturing process,because a traditional roller-dried product was obtained by roller-dryinga cooked slurry mainly comprising cereal flour and 40-45% water, withthe slurry having been cooked in a vat and the drying effect beingobtained by pure heat transfer from the roller to the film of slurryapplied on its surface.

On the other hand, a traditional cooked-extruded product was subjectedto high shear during its manufacturing process, because it was subjectedto high pressure and friction while being cooked in the extruder.

The process of Geromini et al. mentioned above in fact comprisesextrusion-cooking the mixture of water and flour before pressing itthrough an extrusion die with the aid of a gear pump.

On the contrary, the whole process of Juengling et al. mentioned aboveis carried out while maintaining the temperature of the mixture of waterand flour or semolina below 55° C. so that a raw pasta is obtained,without any gelatinization of the flour or semolina. Neither process canaccomplish the desired objectives.

In view of these deficiencies of the prior art, there is a need forimproved processes and products with improved properties, and these arenow provided by the present invention.

SUMMARY OF THE INVENTION

The present invention relates to a process for the manufacture of cookedcereals or dry pet food. This process comprises preparing a mixture ofwater and a dry premix mainly comprising cereal flour or semolina, andpressing the mixture using a gear pump comprising two toothed wheelswhich mesh with each other with the teeth being configured anddimensioned to avoid shearing the mixture as they mesh. The gear pumpforces the mixture first into a heat exchanger and then through anextrusion die to form an extruded product. Also, the mixture is cookedin the heat exchanger to provide a gelatinization degree of at least 85%before passing through the extrusion die. The resulting extruded producthas properties which are similar to those of a roller dried product thatis not subjected to stress during manufacture. Preferably, the gear pumpis operated to impart organoleptic properties to the extruded productwhich are superior to those of an extruded product that is subject topressure and friction while being cooked in an extruder.

The invention also relates to an apparatus for the manufacture of cookedcereals or dry pet food, which comprises, in series, a mixing device forpreparing a mixture of the water and dry premix, a gear pump of the typedescribed above and being located downstream of the mixing device, aheat exchanger located downstream of the gear pump for cooking themixture, and an extrusion die forming an outlet of the apparatus forextruding the cooked mixture as an extruded product.

If desired, the apparatus further comprises an inlet hopper forintroducing the water and dry premix into the mixing device and acutting device operatively associated with the extrusion die for cuttingthe extruded product into predetermined smaller length segments.

In the process and apparatus, the gear pump is generally operated toexert a pressure of (a) from 100 to 200 kPa upstream of the pump; (b)from 3,000 to 25,000 kPa upstream of the heat exchanger; and (c) from2,000 to 10,000 kPa downstream of the heat exchanger. Also, the mixtureis preferably cooked by progressively heating it to 90-180° C. for 2 to15 minutes as the mixture passes through the heat exchanger.

The invention also relates to a cooked cereal product or dry pet foodobtainable by the process or apparatus described herein. The cookedcereal product or dry pet food typically includes one or a combinationof the following properties:

organoleptic properties which are superior to those of an extrudedproduct that is subject to pressure and friction while being cooked inan extruder.

an expansion degree of from 1.5 to 10;

a gelatinization degree of at least 85%,

a starch profile that is similar to that of a roller dried product thatis not subjected to stress during manufacture and that is characterizedby respective proportions of 40-70% amylopectin, 5-22% intermediates and15-35% amylose; and

-   -   a water content of 12-45%.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Embodiments of the present apparatus are described below by way ofexample only with reference to the accompanying drawings in which:

FIG. 1 is a schematic view of an embodiment of the present apparatus,

FIG. 2 is a schematic view of a heat exchanger static mixer which may beused in the embodiment of the apparatus represented in FIG. 1, and

FIG. 3 is a schematic view of another heat exchanger static mixer whichmay be used in an embodiment of the apparatus similar to the onerepresented in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The process for the manufacture of cooked cereal products or dry petfood according to the present invention generally comprises preparing amixture of water and a dry premix mainly comprising cereal flour orsemolina, and pressing the mixture, with the aid of a gear pump, firstlythrough a heat exchanger wherein it is cooked and then through anextrusion die. Likewise, the apparatus for the manufacture of cookedcereal products or dry pet food according to the present inventioncomprises a mixing device, a gear pump, a heat exchanger and anextrusion die connected in series.

Throughout the present specification and claims, the expression “mainlycomprising cereal flour or semolina” means comprising at least 50% orpreferably at least 70% of cereal flour or semolina.

Similarly, the expression “a mixture of water and a dry premix” means“either a mixture of water and dry premix or a mixture of steam, waterand dry premix”.

It has been observed, surprisingly, that it is possible with such aprocess and such an apparatus to maintain the starch's molecularstructure in order to manufacture a cooked cereal product or dry petfood with properties close to those of a traditional roller-driedproduct and superior to those of a traditional cooked-extruded product.

This fact may especially be observed by comparing the respectivegelatinization degrees and starch profiles.

The degree of gelatinization indicates the efficiency of the heatexchanger and how well the product was cooked. Typically, gelatinizationof at least 85%, preferably of 90% or more indicates a sufficientlycooked cereal. The starch profile describes the repartition of the twofunctional molecules of starch, amylose and amylopectin that directlyinfluence important properties of the final product (e.g. viscosity,texture, solubility, and stickiness). Mechanical stress as applied intraditional single- and twin-screw extrusion mainly destroys theamylopectin fraction thus reducing viscosity and increasing solubilityand stickiness. This is why existing products made with low-sheartechnologies (roller drying, high moisture cooking) cannot be exactlycopied by extrusion. Therefore, the present process aims to maintain theinitial starch profile by reducing shear. This is the precondition toobtaining products with properties similar to those of roller dried orhigh moisture cooked products.

Thus, the product obtainable by the present process and apparatuspreferably has a gelatinization degree of at least 85%, more preferablyof 90% or more.

It also preferably has a starch profile characterized by respectiveproportions of 40-70% amylopectin, 5-22% intermediates and 15-35%amylose.

In addition, the present product preferably has an expansion degree offrom 1.5 to 10, more preferably of from 2 to 6.

To carry out the present process for manufacturing cooked cereals, it ispossible to prepare a dry premix comprising 70-88% of a flour orsemolina of a cereal such as wheat, oat, corn and/or rice, and up to 20%of sugars such as sucrose and dextrose, to which other traditionalingredients may be added such as up to 2% of sodium chloride, up to 8%of oil or fat such as vegetable oil or fat or butter oil, up to 15% ofmodified starches such as modified corn or wheat starches, up to 10% ofpowdered milk or other protein source, up to a few % of cocoa powder, upto a few % of malt, up to 0.5% of mineral salts, up to 0.5% of vitamins,up to 2% antioxidants, and possibly even enzymes which can reduce theviscosity of the mixture to be prepared, for example.

For manufacturing dry pet food, it is possible to prepare a dry premixcomprising at least 50% of cereal flour, 25-35% of meat flour and animalby-products, 5-15% fat and tallow, up to 10% vegetable by-products andup to 6% vitamins and minerals, for example.

For manufacturing either cooked cereals or dry pet food it is possiblewith the mixing device to prepare a mixture of water and the premix suchthat the mixture has a water content of 12-45%, preferably of 12-30% andmore preferably of 12-22% by weight.

The still un-cooked mixture is then pressed into the heat exchanger withthe aid of a gear pump. To this end the gear pump may be fed with thismixture in a continuous, steady way, while exerting on it a relativelylow pressure of the order of from about 100 to 2000 kPa upstream of thegear pump.

It is then possible to have the gear pump exerting a pressure of from3000 to 25000, preferably from 4000 to 20000 and more preferably from5000 to 16000 kPa on the mixture upstream of the heat exchanger.

Because the residence time in the gear pump is short and the mechanicalenergy input is low, the original raw materials may reach the heatexchanger without any major molecular degradation.

It is possible to cook this mixture by progressively heating it to90-180° C., preferably to 100-160° C. for 2 to 15 minutes along the heatexchanger, for example.

The cooking in the heat exchanger occurs by mainly thermal heat transferthus maintaining the original molecular structure. The properties ofsuch a cooked product will be close to that of a traditionalroller-dried product and superior to that of a traditionalcooked-extruded product.

In order to press the mixture through said extrusion die, it is possibleto maintain a pressure of from 2000 to 10000, preferably from 3500 to9000 and more preferably from 4000 to 8000 kPa downstream of the heatexchanger and upstream of the die. The pressure loss across the heatexchanger may be between 1000 and 20000, preferably between 1000 and17000, and more preferably between 1000 and 12000 kPa.

It is possible to cut the extruded rope of cooked mixture thus obtainedinto pellets or puffs just at the exit of the die with the aid of acutting device.

As to the present apparatus, the mixing device may be a high speed blademixer, a twin-screw intermeshing and co-rotating mixer or extruder, or asingle-screw extruder.

The heat exchanger preferably is a static mixer heat exchanger. Thestatic mixer may be of any adequate type such as the one disclosed inU.S. Pat. No. 5,486,049 (Boatman et al.) or U.S. Pat. No. 5,538,748(Boatman et al.) or those equipping standard SULZER tubular heatexchangers such as SULZER's SMR DN80 type static mixer heat exchanger,for example.

The gear pump may comprise trio toothed wheels, or toothed rollers whichmesh with each other. The two rollers can rotate in a housing on axlessituated in a plane perpendicular to the direction of a mixture stream.They can each rotate in the opposite direction, the teeth coming apartupstream and closing again downstream. The outer edge of the teeth canslide against a corresponding inner wall of said housing, thus defininginterstitial spaces intended for transporting the mixture to be extrudeddownstream. The shape of the teeth may be especially designed to avoidas much possible any shearing on the mixture.

The extrusion die may comprise one or more extrusion conduits,especially cylindrical conduits, generally oriented in the samedirection as that of a stream of cooked mixture to be extruded, forexample. The shape of the extruded rope may be determined in particularby the shape of the outlet opening or orifice of the conduits.

A typical cutting device comprises a rotating knife.

As represented in FIG. 1, the present apparatus comprises a mixingdevice 1, a gear pump 2, a heat exchanger 3/4, and an extrusion die 5connected in series.

For carrying out the present process, the mixer 1 may be fed with thedifferent components of the mixture through a hopper 6. At a downstreamend of the mixer 1, a still uncooked but homogeneous mixture may beobtained. The gear pump 2 may be fed with this mixture in a continuous,steady way. The mixture may be pressed by the gear pump 2 firstlythrough the heat exchanger 3/4 (under the effect of a pressure p₂exerted upstream of the heat exchanger), where it is cooked, and thenthrough the die 5 (under the effect of a pressure p₁ maintaineddownstream of the heat exchanger and upstream of the die).

In the embodiment represented in FIG. 2, the heat exchanger comprisestwo double jacketed, heatable barrels 3 and 4 filled with non heatablestatic mixers 7.

In the embodiment represented in FIG. 3, the heat exchanger comprisesone non heatable barrel 8 filled with a heatable static mixer 9.

EXAMPLES

The process and the product according to the present invention aredescribed in greater detail in the examples presented below by way ofillustration. The percentages are given therein by weight.

Example 1

An apparatus corresponding to the embodiment represented in FIG. 1 wasused, which comprised a mixer in form of a twin screw side-feeder, aVacorex 70/70 type MAAG gear pump, a heat exchanger as disclosed in U.S.Pat. Nos. 5,486,049 or 5,538,748 and represented in FIG. 2, and a die inform of a steel plate provided with four cylindrical conduits eachhaving a circular outlet opening 4 mm in diameter.

A mixture of rice flour and water having a water content of 34% wasprepared in the mixer which was fed with 48.2 kg/h of rice flour and16.8 kg/h of water.

The mixture was pressed by the gear pump through the heat exchangerunder a pressure p₂ of 12200 kPa. The double jacketed barrels of theheat exchanger were heated to a temperature of 130° C. with highpressure water. The mixture was thus cooked by having it heated to 117°C. in a few min through the heat exchanger.

The pressure loss along the heat exchanger was 9800 kPa so that themixture was then pressed through the die under a remaining pressure of2400 kPa.

The product thus obtained had a gelatinization degree of 90.3%.

The product had a starch profile characterized by respective proportionsof 59.4% amylopectin, 15.2% intermediates and 25.4% amylose.

Example 2

An apparatus corresponding to the embodiment represented in FIG. 1 wasused, which comprised a mixer in form of a twin screw side-feeder, aVacorex 70/70 type MAAG gear pump, an SMR DN80 type SULZER static mixerheat exchanger such as represented in FIG. 3, and a die in form of asteel plate provided with two cylindrical conduits each having acircular outlet opening 4 mm in diameter.

A mixture of rice flour and water having a water content of 30% wasprepared in the mixer which was fed with 51.1 kg/h of rice flour and16.8 kg/h of water.

The mixture was pressed by the gear pump through the heat exchangerunder a pressure p₂ of 12200 kPa. The static mixer of the heat exchangerwas heated to a temperature of 130° C. with high pressure water. Themixture was thus cooked by having it heated to 102° C. in a few minthrough the heat exchanger.

The pressure loss along the heat exchanger was 6900 kPa so that themixture was then pressed through the die under a remaining pressure of5300 kPa.

The product thus obtained had a gelatinization degree of 92.1%.

The product had a starch profile characterized by respective proportionsof 65.0% amylopectin, 16.7% intermediates and 18.3% amylose.

Example 3

The same apparatus was used as in Example 2.

A mixture having a water content of 27% was prepared in the mixer whichwas fed with 51.6 kg/h of a premix comprising 85% rice flour and 15%sugar, 13.4 kg/h of water and 0.5 kg/h of oil.

The mixture was pressed by the gear pump through the heat exchangerunder a pressure p₂ of 10900 kPa. The static mixer of the heat exchangerwas heated to a temperature of 150° C. with high pressure water. Themixture was thus cooked by having it heated to 118° C. in a few minthrough the heat exchanger.

The pressure loss along the heat exchanger was 5500 kPa so that themixture was then pressed through the die under a remaining pressure of5400 kPa.

The product thus obtained had a gelatinization degree of 93.3%.

The product had a starch profile characterized by respective proportionsof 57.9% amylopectin, 20.7% intermediates and 21.4% amylose.

Example 4

The same apparatus was used as in Example 2.

A mixture having a water content of 20.3% was prepared in the mixerwhich was fed with 57.1 kg/h of a premix comprising 55% rice flour, 28%corn semolina, 13% sugar and malt and 4% cocoa powder, 7.9 kg/h of waterand 2.3 kg/h of oil.

The mixture was pressed by the gear pump through the heat exchangerunder a pressure p₂ of 13500 kPa. The static mixer of the heat exchangerwas heated to a temperature of 150° C. with high pressure water. Themixture was thus cooked by having it heated to 121° C. in a few minthrough the heat exchanger.

The pressure loss along the heat exchanger was 6000 kPa so that themixture was then pressed through the die under a remaining pressure of7500 kPa.

The product thus obtained had a gelatinization degree of 85% and anexpansion degree of 1.5.

The product had a starch profile characterized by respective proportionsof 51.6% amylopectin, 20.2% intermediates and 28.2% amylose.

Comparative Example

For the purpose of comparison with the product obtained in Example 4 acomparative sample was produced from the same starting mixture but usinga BC72H type CLEXTRAL twin-screw extruder instead of the presentapparatus.

The extruder was provided with a die in form of a steel plate providedwith six cylindrical conduits each having a circular outlet opening 3 mmin diameter.

The extruder was fed with about 3.5 times the amount of starting mixturewith whom the mixer was fed in Example 4.

The extruder barrels were heated to achieve the same product temperatureas in the SULZER heat exchanger.

The comparative product thus obtained had a gelatinization degree of84%.

The comparative product had a starch profile characterized by respectiveproportions of 28.3% amylopectin, 48.3% intermediates and 23.4% amylose.

Thus the relatively low proportion of amylopectin remaining in thecomparative product and the relatively high content in intermediatesfound in the comparative product stood in surprisingly stark contrastwith the relatively high proportion of amylopectin maintained in theproduct of Example 4 and the relatively low content in intermediatesfound in the product of Example 4.

1. A process for the manufacture of cooked cereals or dry pet food, theprocess comprising preparing an uncooked mixture of water and a drypremix mainly comprising cereal flour or semolina, pressing the uncookedmixture using a gear pump comprising two toothed wheels which mesh witheach other with the teeth being configured and dimensioned to avoidshearing the uncooked mixture as they mesh, with the gear pump forcingthe uncooked mixture first into a heat exchanger and then through anextrusion die to form an extruded product; and cooking the uncookedmixture in the heat exchanger to provide a gelatinization degree of atleast 85% before the cooked mixture passes through the extrusion die;the extruded product comprising a starch profile having respectiveproportions of 40-70% amylopectin, and 15-35% amylose.
 2. The process ofclaim 1 wherein the mixture is cooked in the heat exchanger to provide agelatinization degree of at least 90% before the mixture passes throughthe extrusion die.
 3. The process of claim 1 wherein the product isextruded through the extrusion die to an expansion degree of 1.5 to 10.4. The process of claim 1 wherein the product is extruded through theextrusion die to an expansion degree of 2 to
 6. 5. The process of claim1, which comprises preparing a mixture of water and the premix such thatthe mixture has a water content of 12-45%.
 6. The process of claim 1wherein the premix contains at least 70% of cereal flour or semolina. 7.The process of claim 1, which further comprises operating the gear pumpto exert a pressure of (a) from 100 to 200 kPa upstream of the pump; (b)from 3,000 to 25,000 kPa upstream of the heat exchanger; and (c) from2,000 to 10,000 kPa downstream of the heat exchanger.
 8. The process ofclaim 7, wherein the gear pump is operated to exert a pressure of from4,000 to 20,000 kPa upstream of the heat exchanger; and from 3,500 to9,000 kPa downstream of the heat exchanger.
 9. The process of claim 7,wherein the gear pump is operated to exert a pressure of from 5,000 to16,000 kPa upstream of the heat exchanger, and from 4,000 to 8,000 kPadownstream of the heat exchanger.
 10. The process of claim 1, whereinthe mixture is cooked by progressively heating the mixture to 90-180° C.for 2 to 15 minutes as the mixture passes through the heat exchanger.